Method of molding synthetic resins



: m a Nov. -12,- 1929 ,1.

.qg -om'rim s 'mxres P TE T ounce rmlr 3.3mm; or nonnisrown, AND nonmvr names, or VILLANOVA, rnmn SYLVANI A, ASSIGNOBS, BY MESNE ASSIGNMENTS, T CONTINENTAL-DIAMOND FIBRE COMPANY, OF NEWARK, DELAWARE, CORPORATION OF DELAWARE METHOJS OF MOLDING SYNTHETIC RESINS a Ito Drawing.

Our invention relates to arocess for the molding of synthetic resins an more particularly to those synthetic resins which are at .the present time converted from the initial or soluble-fusible stage to the final or insolubleinfusible stage by heat and pressure.

One object of our invention is to provide a novel method ofmolding synthetic resins whereby it is possible to shorten the time required for the pressing operation and therefore to increase the production of a given unit.

Anotherobjectofour invention is to provide a cold pressing process which results in a isagreat saving in the wear of the hydraul c presses since by following the process of this invention, it is not necessary alternately to heat and cool the press, with the resulting corrosion and wear of the metal, packing,

' valves and other mechanisms.

A further object is to provide a simple and expedient method of molding synthet c resins by which the molding costs are considerably reduced Without im airing the quality of the finshed product. ther objects w1ll be apparent from a consideration of the spec fication and claims.

This invention is applicable to various types. of synthetic resins which are now treated in the molds under heat and pressure.

' It is particularly applicablev to those res ns known to the art as phenolic condensat on piteaducts. These are typical of the reslns which exist in two stages, the first stage 'known as the initial stage in which the resln is fusible and soluble and the second stage known as thefinal stage in which the resin is insoluble and infusible. The change from the initial stage to the final stage is at the present time accomplished by simultaneously subjecting the resin to heat and pressure. Our invention is not only applicable to phenolic condensation roducts but also to such other synthetic reslns as are'treated by heat and pressure such as those having urea or,phthalic anhydride as one initial constitucut. This simultaneous subjection of the resin to heat and pressure takes a considerable length of time, since it is necessary to heat .5 the initial mass and then to bring about the Application filed August 2, 1928. Serial No. 287,097.

chemical reaction. This time factor determines the production of the presses and hence a given unit is limited in the amount of material treated- Furthermore, the heat required in the presses causes wear and corrosion and the alternate coolingand heating of the presses is not only expensive but causes great wear on the metal parts, the packing, valves and other mechanical elements of the presses. f

Our invention is characterized by a cold pressing operation, that is to say by following the present invention,'it is not necessary to subject the resin to heat and pressure simultaneously but the heat is first applied and when the mass is sufficiently heated and while still in a heated condition, it is placed in a cold mold and formed to the desired shape under pressure.

At the present time, synthetic resins are generally used in conjunction with fillers which may be either in fibrous or granular condition or in the form of sheet material such as paper sheets or cloth. When granular or fibrous materials are used, the resin in a finely divided condition is usually mixed with the filler and the mixture then placed in a hydraulic press and subjected to heat and pres sure. In the manufacture of products involving sheet material, it is customaryto impregnate the sheet by means of a solution of the synthetic resin in an organic solvent, such as alcohol. The solvent is later evaporated and the treated sheetsare out to the desired size and superimposed one above the other until the desired thickness is obtained. The stack of superimposed sheets are then placed in a platen hydraulic press and molded under heat and pressure,

The process of the present invention may be satisfactorily employed both when molding the synthetic resin alone and when molding the resin in conjunction with a filler. In using fillin materials, the processing prior to the mol ing step, that is to say the bringing together of the filler and the synthetic resin,-is accomplished in accordance with any of thejvell known practices of the art.

The material to be molded is heated by a y'de i e m a t a p a ure and for time an must not be heated beyond the stage where a time suflicient to' insure conversion to the final stage after treatment in the hydraulic press. Both the temperature and time may vary widely but they are somewhat dependent on each other. For example, the use ofa high tem rature allows heating for a shorter vice versa: The mass, however,

mangoes the initial condensation product at approximately 300 F. for approximately 20 minutes and thereafter while the mass isstill hot and under su cient pressure to obtain the molded form desired,

FRANK H. BENGE.

ROBERT R. TITUS.

Iii a specific case, a of phe'nol-form- 4 inch is applied for 5 minutes. ollowing the old molding process,'the time in the hydraulic presswas approximately min: utes. Thus it will be 'seen that the production of a iven unit is very materially increased. The product obtained by following the present invention is of similar qualityas that now obtained by the simultaneous heat and pressure treatment.

Considerable modification is possible in the temperature emplo ed and in the time of heating as well as in t e degree of pressure and the time of pressing.

Weclaim'z- '1. The method of molding synthetic resins which'com rises heating the initial condensation pro uct of a synthetic resin at a temperature and for a time which will cause the resin to. be converted into the final stage after the pressing operation, placing thehot lastic' placing it in a cold press plastic mass in a cold press and while the mass is still hot exerting suflicient pressure to obtain the molded form desired.

2. The method of molding phenolic condensation products which comprises heating the initial condensation product of aphenolic condensation product at a temperature and for a time which will cause the resinto be converted into the final stage after the pressing operation, placing the 'hotplastic mass in a cold press and while the mass is still hot exerting suflicient pressure to obtain the molded form desired. 1

3. The method of molding phenolic condensation products which comprises heating the initial condensation product at approxi-. mately 300 F. for approximately 20 minutes and thereafter while the mass is still hot and lastic placing it in a cold press under su c'ient pressure to obtain the molded form desired. 1

'4. The method .of molding phenol-formaldehyde products which comprises heating 

